MUSTART
Intermittent Cable Conductor or Pilot Wire Break
Charger works intermittently when the cable is moved or bent; charging may start or stop when the cable is jiggled.
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Safety Warning
This repair may involve working with high voltage components or water connections. Always unplug the appliance before removing any panels.
If you are not confident in your ability to perform this repair safely, we strongly recommend contacting a professional technician.
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Possible Causes
Broken conductor inside cable near strain relief, damaged pilot or proximity wire, repeated sharp bending of cable, manufacturing defect in crimp or solder joint
How to Fix / Troubleshooting
Safety warning: Do not continue using a cable that starts and stops charging when moved; this can cause arcing and overheating.
- Reproduce safely: With the charger powered but not charging, gently move the cable near the handle and near the charger housing to see if the display or status changes.
- Inspect strain reliefs: Look for cracks or gaps where the cable enters the J1772 handle and the charger housing.
- Retire damaged cable: If movement clearly affects operation, stop using the charger until the cable assembly is replaced.
- Replacement: Order a compatible MUSTART J1772 charging cable assembly or have the manufacturer service the unit.
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Repair Difficulty
Medium
3/5
Required Part
J1772 Charging Cable Assembly
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